Machining of Metal Matrix Composite - process modelling, tool wear and surface integrity

金属基复合材料加工 - 工艺建模、刀具磨损和表面完整性

• 批准号: RGPIN-2015-04030
• 负责人: Kishawy, Hossam
• 金额: $ 1.82万
• 依托单位: University of Ontario Institute of Technology
• 依托单位国家: 加拿大
• 项目类别: Discovery Grants Program - Individual
• 财政年份: 2016
• 资助国家: 加拿大
• 起止时间: 2016-01-01 至 2017-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=612731
• 关键词: Machining; Metal; Matrix; Composite; process

During the past decades, Metal Matrix Composites (MMCs) have received considerable interests in several manufacturing sectors including the automotive and aerospace industries which represent a major sector of the Canadian manufacturing economy. MMCs possess superior physical and mechanical properties compared to non-reinforced alloys. Therefore, they are being considered as a replacement material for the conventional alloys in many engineering applications. Their unique physical properties give them a great potential; however, MMCs face challenges in order to have a wide spread MMCs substitution for monolithic materials. The presence of abrasive reinforcements in the ductile matrix causes severe tool wear and premature tool failure during machining operation. Although efforts have been made to produce MMCs parts by casting, or hot forging, the resulted near net-shape products still have to be machined into the final shape and dimension with the required accuracy. Cracking and debonding of the reinforcement particles are the significant damage modes of machined surface and also the subsurface damage assessment is critical for machined components subjected to fatigue, especially in critical application such as aerospace. The changes in the machined surface physical properties and machining induced residual stresses are attributed to both mechanical as well as thermal load (heat generated). One way to overcome this challenge is by reducing/eliminating the harmful effect of tool wear. The previous successful application of self-propelled rotary tool in cutting other difficult to cut materials has made it a good candidate for better control of tool wear and tool life when cutting MMC.           In view of the growing application of these materials, the detailed study of their machined surface integrity and improvement of their cutting process efficiency is required. This study will focus on the above mentioned challenges through detailed surface integrity study of machined MMC surfaces and provide the needed knowledge and expertise to enable the wide use of this material in several Canadian industries.

在过去的几十年里，金属基复合材料（MMC）在几个制造业部门，包括汽车和航空航天工业，代表了加拿大制造业经济的主要部门，收到了相当大的兴趣。与非增强合金相比，金属基复合材料具有上级物理和机械性能。因此，在许多工程应用中，它们被认为是传统合金的替代材料。其独特的物理性能使其具有巨大的潜力，然而，金属基复合材料面临的挑战，以有一个广泛的金属基复合材料替代单片材料。韧性基体中磨料增强物的存在导致严重的刀具磨损和加工操作期间的刀具过早失效。尽管已经努力通过铸造或热锻造来生产MMCs部件，但是所得到的近净形产品仍然必须以所需的精度加工成最终形状和尺寸。增强颗粒的开裂和脱粘是机械加工表面的重要损伤模式，并且亚表面损伤评估对于经受疲劳的机械加工构件是至关重要的，特别是在关键应用如航空航天中。机械加工表面的物理性能和机械加工引起的残余应力的变化归因于机械负荷和热负荷（产生的热量）。克服这一挑战的一种方法是减少/消除刀具磨损的有害影响。自走式旋转刀具在切削其他难切削材料方面的成功应用使其成为切削MMC时更好地控制刀具磨损和刀具寿命的良好候选者。 鉴于这些材料的日益广泛的应用，需要对其加工表面完整性进行详细的研究，并提高其切削加工效率。本研究将通过对机加工MMC表面进行详细的表面完整性研究，重点关注上述挑战，并提供所需的知识和专业知识，使这种材料在加拿大的几个行业中得到广泛使用。